Stiction alleviation using passivation layer patterning

ABSTRACT

The present invention alleviates stiction between a suspended beam or microstructure and an underlying substrate by providing a patterned passivation layer on the substrate underneath the beam. The passivation layer is patterned to provide a substrate surface that differs substantially from the bottom surface of the beam. The difference between these two surfaces reduces the potential contact area between the beam and the substrate when the beam is pulled down, thereby reducing adhesive forces between the beam and the substrate and reducing the likelihood of stiction. In one embodiment, the passivation layer is patterned to form a substrate surface comprising a plurality of protuberances. In another embodiment, the passivation layer is patterned to form a substrate surface having a mesh pattern.

TECHNICAL FIELD

[0001] The invention relates to stiction alleviation, and more particularly to stiction alleviation using a patterned passivation layer.

BACKGROUND OF THE INVENTION

[0002] Micro-Electro-Mechanical System (MEMS) devices find applications in a variety of fields, such as communications, sensing, optics, micro-fluidics, and measurements of material properties. In the field of communications, variable MEMS capacitors are used in tunable RF filter circuits. The MEMS capacitors offer several advantages over solid state varactor diodes, including a higher on/off capacitance ratio and a higher Quality (Q) factor. In addition, MEMS devices offer greater linearity compared to their solid state counterparts, which reduces intermodulation products when used in Radio Frequency (RF) applications.

[0003] Many of these MEMS devices comprise a beam or microstructure suspended above a substrate by one or more supports. In a variable MEMS capacitor, for example, the beam may be suspended above a bottom electrode on the substrate to form a capacitor with the beam acting as the top electrode. The capacitance of the variable MEMS capacitor is varied by establishing an electrostatic force between the beam and the bottom electrode. The electrostatic force bends the beam relative to the bottom electrode, thereby changing the gap between the beam and the bottom electrode and, therefore, the capacitance of the MEMS capacitor.

[0004] A problem in MEMS devices is permanent adhesion of the beam or microstructure to the underlying substrate. This phenomenon is commonly referred to as “stiction”. Stiction typically occurs when a beam or other microstructure is brought into intimate contact with the substrate. Once in contact, adhesion forces, e.g., Van der Waals force and/or hydrogen bonding, on the surface of the substrate exceed the elastic restoring force of the beam. As a result, the beam remains stuck to the substrate, rendering the MEMS device unusable.

[0005] Stiction may occur during fabrication of a MEMS device. For example, stiction may occur when a sacrificial layer used to temporary support the beam during fabrication is removed to release the beam. The sacrificial layer is often removed using a wet enchant followed by a rinse with a liquid agent, e.g., deionized (DI) water and/or methanol. As the device dries, liquid agent trapped between the beam and the substrate may produce capillary forces sufficient to pull down the beam into intimate contact with the substrate. Stiction may also occur during operation of a MEMS device, sometimes referred to as “in-use” stiction. For example, stiction may occur in a MEMS capacitor when the electrostatic force used to vary the capacitance of the MEMS capacitor pulls down the beam into intimate contact with the substrate.

[0006] Several approaches have been developed to alleviate stiction. One approach is to provide a rough surface on the substrate underlying the beam to reduce adhesion forces between the beam and the substrate. This is commonly done by depositing a nitride layer onto the substrate and wet etching grain boundaries in the nitride layer to produce a rough surface. A drawback of this approach is that “pin-holes” sometimes form in the nitride layer, which can lead to premature breakdown of the device. Another approach is to provide “dimples” or small bumps on the bottom surface of the beam to prevent the beam from coming into intimate contact with the substrate. A drawback of this approach is that it involves a cumbersome fabrication process that requires a planarization step, which may not be feasible in some process flows. Yet another approach is to use hydrophobic monolayers known as self assembled monolayers or SAM coatings to make the beam hydrophobic. This reduces the likelihood that water droplets will form under the beam and pull the beam down into intimate contact with the substrate.

SUMMARY OF THE INVENTION

[0007] The present invention alleviates stiction between a suspended beam or microstructure and an underlying substrate by providing a patterned passivation layer on the substrate underneath the beam. The passivation layer is patterned to provide a substrate surface that differs substantially from the bottom surface of the beam. The difference between these two surfaces reduces the potential contact area between the beam and the substrate when the beam is pulled down, thereby reducing adhesive forces between the beam and the substrate and the likelihood of stiction.

[0008] In one embodiment, a bottom electrode is provided on the substrate to form a variable MEMS capacitor with the suspended beam acting as the top electrode of the MEMS capacitor.

[0009] In another embodiment, the passivation layer is patterned to form a substrate surface comprising a plurality of protuberances.

[0010] In still another embodiment, the passivation layer is patterned to form a substrate surface having a mesh pattern.

[0011] In yet another embodiment, a bottom dielectric layer is provided between the patterned passivation layer and the substrate.

[0012] Other objects and features of the present invention will become apparent from consideration of the following description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 shows a MEMS structure comprising a patterned passivation layer for alleviating stiction according to an embodiment of the invention.

[0014]FIG. 2 shows a MEMS capacitor comprising a bottom electrode underneath the patterned passivation layer according to another embodiment of the invention.

[0015]FIG. 3A is a top view of a passivation layer patterned into a plurality of square protuberances.

[0016]FIG. 3B is a top view of a passivation layer patterned into a plurality of rectangular protuberances.

[0017]FIG. 3C is a top view of a passivation layer patterned into a plurality of hexagonal protuberances.

[0018]FIG. 3D is a top view of a passivation layer patterned into a square mesh.

[0019]FIG. 3E is a top view of a passivation layer patterned into a hexagonal mesh.

[0020]FIG. 3F is a top view of a passivation layer patterned into a checkerboard mesh.

[0021] FIGS. 4A-4K show a process flow for fabricating the MEMS structure of FIG. 1 according to an embodiment of the invention.

[0022] FIGS. 5A-5H show a process flow for fabricating the MEMS capacitor of FIG. 2 according to another embodiment of the invention.

[0023]FIG. 6 shows a MEMS structure comprising a bottom dielectric layer underneath the patterned passivation layer according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0024] Referring to FIG. 1, a MEMS structure 10 according to an embodiment of the invention is shown. The MEMS structure 10 comprises a substrate 15, a passivation layer 20 on the substrate 15, and a beam 25 suspended above the substrate 15. The substrate 15 may be made of silicon, MgO, Alumina, quartz, Gallium Arsinide (GaAs), or other suitable material. The passivation layer 20 may be made of a dielectric material, including, but not limited to, Silicon Nitride (Si₃N₄), Silicon Oxide (SiO₂), Strontium Titanate Oxide (SrTiO₃), polyimide, Barium Strontium Titanate (BST), and Benzocyclobutene (BCB). The beam 25 is suspended above the substrate 15 by two anchors 30 attached to each end of the beam 25. Alternatively, the beam 25 may be supported by a single anchor attached to one of its ends. The beam 25 may be made of a metal characterized by excellent flexibility, a high electrical conductivity and ease of deposition or may be made of other conductive material such as doped polysilicon. Suitable metals for the beam 25 include, but are not limited to, gold and silver. For RF applications, a low loss metal is preferred.

[0025] To alleviate stiction between the beam 25 and the substrate 15, the passivation layer 20 underlying the beam 25 is patterned to provide a substrate surface that differs from the bottom surface 27 of the beam 25. In the illustrative example in FIG. 1, the bottom surface 27 of the beam 25 is substantially flat, while the passivation layer 20 is patterned to form a substrate surface comprising a plurality of spaced protuberances 40. The difference between these two surfaces reduces the potential contact area between the beam 25 and the substrate 15 when the beam 25 is pulled down, thereby reducing adhesive forces between the beam 25 and substrate 15 and the likelihood of stiction.

[0026] Referring to FIG. 2, a variable MEMS capacitor according to an embodiment of the invention is shown. The MEMS capacitor is similar to the MEMS structure in FIG. 1, but further comprises a bottom electrode 115 on the substrate 20 and underneath the patterned passivation layer 20. The MEMS capacitor also comprises contact electrodes 120 on the substrate 20 and underneath at least one of the anchors 30. The electrodes 115, 120 may be made of metal, High Temperature Superconductor (HTS) material or other conductive material. In this embodiment, the suspended beam 25 acts as a top electrode of the MEMS capacitor. The gap and dielectric material (i.e., passivation layer 20) between the beam 25 and the underlying bottom electrode 115 determines the capacitance of the MEMS capacitor. The capacitance of the MEMS capacitor is varied by varying a bias voltage applied to the capacitor. The applied bias voltage establishes an electrostatic force on the beam 25 that bends the beam 25 relative to the bottom electrode 115, thereby varying the gap between the beam 25 and the bottom electrode 115. This is turn varies the capacitance of the MEMS capacitor. The passivation layer 20 overlying the bottom electrode 115 is patterned into a plurality of spaced protuberances 40 to alleviate stiction, e.g., “in use” stiction associated with electrostatic pull down of the beam 25.

[0027] Referring to FIGS. 3A-3F, the top view of patterned passivation layers 20 according to several embodiments of the invention are shown. In each of these embodiments, the passivation layer 20 is patterned to provide a substrate surface that differs from the flat bottom surface 27 of the beam 25 to alleviate stiction. FIGS. 3A-3C show the passivation layer 20 patterned into a plurality of protuberances 40 having square, rectangular, and hexagonal cross sections, respectively. Spacing the protuberances 40 far apart reduces the potential contact area between the substrate 15 and the beam 25 and, therefore, reduces the likelihood of stiction. In addition, spacing the protuberances 40 far apart reduces the fill-factor of the passivation layer 20, which reduces the lossiness of the passivation layer 20 when used, e.g., in a MEMS capacitor for high frequency applications. Spacing the protuberances too far apart, however, may allow portions of the beam 25 to bend down between adjacent protuberances 40 and make contact with the underlying substrate 15. FIGS. 3D-3F show the passivation layer patterned into a hexagonal mesh, a square mesh, and a checkerboard mesh, respectively. Each of these mesh patterns may be formed by selectively etching voids 130 into the passivation layer 20. For example, the checkerboard mesh in FIG. 3F may formed by etching square voids 130 into the passivation layer 20 in a checkerboard pattern. The patterns shown in FIGS. 3A-3F are for illustrative purposes and are not intended to be exhaustive.

[0028] FIGS. 4A-4K show an exemplary process flow for fabricating the MEMS structure of FIG. 1 according to one embodiment. In FIG. 4A, a substrate 15 is provided. In FIG. 4B, a passivation layer 20 is deposited onto the substrate 15. In FIG. 4C a patterning layer 150, e.g., photoresist, is deposited onto the passivation layer 20. In FIG. 4D, the patterning layer 150 is patterned to have the desired pattern for the passivation layer 20. The pattern may be any one of the patterns shown in FIGS. 3A-3F or another pattern. The patterning layer 150 may be patterned using photolithography, selective laser etching, e-beam writing and the like. In FIG. 4E, the pattern of the patterning layer 150 is transferred to the passivation layer 20 by etching the passivation layer 25 with an etchant, e.g., KOH, that selectively etches away the portions of the passivation layer 20 exposed by the patterning layer 150. In FIG. 4F, the patterning layer 150 is removed, e.g., using acetone.

[0029] Alternatively, the passivation layer 20 may be patterned directly without the use of the patterning layer 150. For example, the passivation layer 20 may be made of a photo-imagable material, e.g., Benzocyclobutene (BSB), that can be patterned directly using UV light. In this example, the passivation layer 20 is patterned by exposing the passivation layer 20 to UV light through a photo mask (not shown) having the desired patterned and then selectively etching away portions of the passivation layer 20 exposed to the UV light, thereby transferring the pattern of the photo mask onto the passivation layer 20.

[0030] In FIG. 4G, a sacrificial layer 160 is deposited onto the patterned passivation layer 20. The sacrificial layer 160 is used to provide mechanical support for the beam 25 and the associated anchors 30 during fabrication. The sacrificial layer 160 may be any suitable material, e.g., a photoresist, a polyimide or an oxide. In FIG. 4H, the sacrificial layer 160 is patterned to form vias 165 in the sacrificial layer 160. At this stage in the process, the top surface of the sacrificial layer 160 may follow the contours of the patterned passivation layer 20, as illustrated in FIG. 4H. This is undesirable because the top surface of the sacrificial layer 160 will later define the bottom surface of the beam 25. In order to obtain a smoother bottom surface for the beam 25, the top surface of the sacrificial layer 160 is smoothed out by subjecting the sacrificial layer 160 to a hard bake at a sufficiently elevated temperature, e.g., at 200° C. The hard bake initially lowers the viscosity of the sacrificial layer 160, causing the top surface of the sacrificial layer 160 to re-flow and smooth out, as illustrated in FIG. 4I. The sacrificial layer 160 then hardens as moisture in the sacrificial layer 160 is evaporated. The re-flow process may also smooth the corners of the vias 165, which is not illustrated in FIG. 4I. In FIG. 4J, a metal or polysilicon layer 170 is deposited onto the sacrificial layer 160 and the vias 165. The metal layer 170 may be deposited using electroplating, sputtering, or e-beam deposition. In FIG. 4K, the metal layer 170 is patterned to form the beam 25 and the anchors 30, and the sacrificial layer 160 is removed to release the beam 25 above the substrate 15. The sacrificial layer 160 may be removed using suitable means, e.g., wet etching the sacrificial layer 160 followed by a rinse with a liquid agent, e.g. deionized (DI) water or methanol. The patterned passivation layer 20 alleviates stiction associated with the liquid agent, thereby increasing the production yield of the MEMS device.

[0031]5A-5H show an exemplary process flow for fabricating the MEMS capacitor of FIG. 2. In FIG. 5A, a substrate 15 is provided. In FIG. 5B, a conductive material is deposited onto the substrate and patterned to form a bottom electrode 115 and two contact electrodes 120. In FIG. 5C, a passivation layer 20 is deposited onto the substrate 15. In FIG. 5D, the passivation layer 20 is patterned to form spaced protuberances 40 over the bottom electrode 115 and vias 175 above the contact electrodes 120. The passivation layer 20 may be patterned using a patterning layer (not shown) or may be patterned directly using a photo-imagable material for the passivation layer 20. In FIG. 5E, a sacrificial layer 180, e.g., photoresist, is deposited onto the passivation layer 20. In FIG. 5F, the portions of the sacrificial layer 180 corresponding to the vias 175 in the passivation layer 20 are etched away. In FIG. 5G, the sacrificial layer 180 is subjected to a hard bake to smooth out the top surface of the sacrificial layer 180. In FIG. 5H, a metal or polysilicon layer is deposited onto the sacrificial layer 180 and patterned to form the beam 25 and anchors 30 of the MEMS capacitor. In addition, the sacrificial layer 180 is removed to release the beam 25 above the substrate 15.

[0032]FIG. 6 shows a MEMS structure according to another embodiment. The MEMS structure is similar to the MEMS structure of FIG. 1, but further comprises a bottom dielectric layer 250 on the substrate 15 and underneath the patterned passivation layer 20. The MEMS structure according to this embodiment may be used to form a MEMS capacitor, e.g., by placing a bottom electrode (not shown) on the substrate 15. The dielectric layer 250 may be polyimide, silicon nitride or other oxide. The dielectric layer 250 may be deposited onto the substrate using standard MEMS fabrication methods. To prevent the dielectric layer 250 from being etched during patterning of the overlying passivation layer 20, the dielectric layer 250 may be solidified before deposition of the passivation layer 20. This may be done, e.g., by exposing the dielectric layer 250 to UV light followed by a hard bake.

[0033] While various embodiments of the application have been described, it will be apparent to those of ordinary skill in the art that many embodiments and implementations are possible that are within the scope of the present invention. For example, even though the patterned passivation layer was described in the context of alleviating stiction between a beam and a substrate, the patterned passivation layer may be used to alleviate stiction between any microstructure and a substrate or between two adjacent microstructures, e.g., by forming the patterned passivation on one of the two adjacent microstructures. Therefore, the invention is not to be restricted or limited except in accordance with the following claims and their equivalents. 

What is claimed is:
 1. A MEMS apparatus, comprising: a substrate; a passivation layer on the substrate, the passivation layer having a top surface; and a microstructure suspended above the substrate, the microstructure having a bottom surface facing the top surface of the passivation layer; wherein the passivation layer is patterned so that the top surface of the passivation layer is substantially different from the bottom surface of the microstructure.
 2. The MEMS apparatus of claim 1, wherein the passivation layer is patterned to form a plurality of spaced protuberances.
 3. The MEMS apparatus of claim 2, wherein the bottom surface of the microstructure is substantially flat.
 4. The MEMS apparatus of claim 2, wherein at least one of the protuberances has a square cross section.
 5. The MEMS apparatus of claim 2, wherein at least one of the protuberances has a rectangular cross section.
 6. The MEMS apparatus of claim 2, wherein at least one of the protuberances has a hexagonal cross section.
 7. The MEMS apparatus of claim 1, wherein the passivation layer is patterned to form a mesh.
 8. The MEMS apparatus of claim 7, wherein the bottom surface of the microstructure is substantially flat.
 9. The MEMS apparatus of claim 7, wherein the mesh is a square mesh.
 10. The MEMS apparatus of claim 7, wherein the mesh is a hexagonal mesh.
 11. The MEMS apparatus of claim 1, wherein the passivation layer comprises polyimide.
 12. The MEMS apparatus of claim 1, wherein the passivation layer comprises silicon nitride.
 13. A MEMS apparatus, comprising: a substrate; a passivation layer on the substrate, the passivation layer having a top surface; a support attached to the substrate; and a beam attached at one end to the support and suspended above the substrate, the beam having a bottom surface facing the top surface of the passivation layer; wherein the passivation layer is patterned so that the top surface of the passivation layer is substantially different from the bottom surface of the beam.
 14. The MEMS apparatus of claim 13, further comprising a second support attached to the substrate and wherein the beam is attached to the second support at a second end.
 15. The MEMS apparatus of claim 13, further comprising a bottom electrode on the substrate and underneath the bottom surface of the beam.
 16. The MEMS apparatus of claim 13, wherein the passivation layer is patterned to form a plurality of spaced protuberances.
 17. The MEMS apparatus of claim 16, wherein the bottom surface of the microstructure is substantially flat.
 18. The MEMS apparatus of claim 16, wherein at least one of the protuberances has a square cross section.
 19. The MEMS apparatus of claim 16, wherein at least one of the protuberances has a rectangular cross section.
 20. The MEMS apparatus of claim 16, wherein at least one of the protuberances has a hexagonal cross section.
 21. The MEMS apparatus of claim 13, wherein the passivation layer is patterned to form a mesh.
 22. The MEMS apparatus of claim 21, wherein the bottom surface of the microstructure is substantially flat.
 23. The MEMS apparatus of claim 21, wherein the mesh is a square mesh.
 24. The MEMS apparatus of claim 21, wherein the mesh is a hexagonal mesh.
 25. The MEMS apparatus of claim 13, wherein the passivation layer comprises polyimide.
 26. The MEMS apparatus of claim 13, wherein the passivation layer comprises silicon nitride.
 27. A method of fabricating a MEMS structure, comprising the steps of: depositing a passivation layer onto a substrate; patterning a predetermined pattern into the passivation layer; depositing a sacrificial layer onto the patterned passivation layer; forming a microstructure on the sacrificial layer such that the microstructure overlaps the patterned passivation layer; and removing the sacrificial layer to release the microstructure above the patterned passivation layer.
 28. The method of claim 27, wherein the predetermined pattern comprises a plurality of spaced protuberances.
 29. The method of claim 28, wherein at least one of the protuberances has a square cross section.
 30. The method of claim 28, wherein at least one of the protuberances has a rectangular cross section.
 31. The method of claim 28, wherein at least one of the protuberances has a hexagonal cross section.
 32. The method of claim 27, wherein the predetermined pattern is a mesh pattern.
 33. The method of claim 32, wherein the mesh is a square mesh.
 34. The method of claim 32, wherein the mesh is a hexagonal mesh.
 35. The method of claim 27, further comprising the step of baking the sacrificial layer prior to forming the microstructure to smooth out the top surface of the sacrificial layer.
 36. The method of claim 27, wherein the step of patterning the passivation layer further comprises: depositing a patterning layer onto the passivation layer; patterning the predetermined pattern into the patterning layer; transferring the predetermined pattern from the patterning layer to the passivation layer; and removing the patterning layer.
 37. The method of claim 37, wherein the patterning layer comprises photoresist.
 38. The method of claim 27, wherein the step of patterning the passivation layer further comprises: exposing the passivation layer to UV light through a photo mask having the predetermined pattern; and selectively etching away portions of the passivation layer exposed to the UV light, thereby transferring the predetermined pattern to the passivation layer. 